A while back, I needed to install a new electrical distribution box in my personal workspace. While this is a job best left to certified professionals, my pride as a self-proclaimed "clumsy technician" wouldn't let me call for help. So, I decided to build one myself.
This post is a record of that past project.
⚠️ Extremely Dangerous: Do Not Attempt Without Professional Qualification
Let's be crystal clear: working with electricity is extremely dangerous and can result in severe injury, fire, or death. This post is a case study of a personal project I completed based on South Korean standards (single-phase 220V / 60Hz) and is NOT a universal tutorial. Do not attempt this unless you are a qualified professional who fully understands the risks and your local electrical codes. I assume no responsibility for any accidents that may occur.
The Heart of the System: Components and Parts
First, I prepared the necessary components for my single-phase 220V system. The key parts were:
1. Enclosure: A steel distribution box (400x500x150mm).
2. Busbar System: A modular "Quick Bar" system (QB-62-32-3P & 1P).
3. Main Breaker: A 60A Molded Case Circuit Breaker (MCCB).
4. Branch Breakers: Six 30A and two 20A Earth Leakage Circuit Breakers (ELCBs).
5. Supports: Mounting supports for the breakers.
The Assembly: A Modern Approach with a Modular Busbar
While I could explain the entire process in text, it's much easier to understand by watching it. The full assembly process from that time is in the video below.
The star of this build was the "Quick Bar" modular busbar system. Compared to traditional busbars, which require cutting and drilling, this system was like assembling LEGOs. You simply snapped the components into place. It was faster, easier, and the result was incredibly clean and professional-looking. Plus, its modular design makes future modifications and expansions much easier.
Final Thoughts and a Reminder on Safety
The box was assembled and has been working perfectly without any issues since then. However, with any electrical work, regular inspection is a must. Just because I was meticulous doesn't mean I can forget about it. In fact, writing this has just reminded me that it's time for a check-up!
This was a satisfying project that showcases a modern, efficient way to build a custom distribution box. But I will say it one last time: safety first. If you have even the slightest doubt, please hire a professional.
